Abstract: A bra cup component has an inner fabric layer with lower, middle and lower cup areas. The lower cup area is knit fabric of a first synthetic yarn that is initially flexible and then becomes more rigid after being heated to a temperature higher than any temperature the bra would experience during washing and wearing. The upper cup area knit of a second polyester yarn. An outer fabric layer over the inner fabric layer is attached around the perimeter and is closely adjacent the upper cup area and spaced from the lower cup area to form a support space. An underwire area is around a lower portion of the lower cup area so that the lower cup area extending between opposite ends of the underwire area for creating a bust lifting effect.

Abstract: A method of manufacturing a breast-covering garment pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each breast summit of the pad or a garment including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the nipples the breasts.

Abstract: A method of manufacturing a pad for a breast covering garment provides a fabric sheet with an upper neckline, a lower channeling and an underarm and adheres a foam sheet of compressible material to the fabric sheet. A first portion of the pad is adjacent and along the upper neckline containing only fabric of the fabric sheet, and a remaining portion of the pad is between the first portion and the lower channeling containing the compressible material of the foam sheet. The method includes providing the foam sheet to have a thickest end at locations of the underarm and the channeling which are spaced away from the neckline, and the foam sheet becomes gradually thinner toward the neckline to a location that is near to, but still spaced from the neckline where the sheet of foam ends at the first portion of the pad.

Abstract: A method is provided for making a bra pad having a rigid foam that is thickest at the bottom of the pad for hidden support and a stretchable softer foam for comfort and universal fit throughout the entire pad. The method includes pre-laminating rigid and stretchable foam sheets with fabric and shaving the foam sheets. The rigid foam sheet is shaved so that it has a V-shaped recess and a gradually sloped interface between the V-shaped recess and remainder of the sheet. The stretchable foam sheet is shaved so that it has a pair of elevated areas. Then, the top surfaces of the shaved foam sheets are affixed together to form a pre-form assembly and the pre-form assembly is molded under heat. The pair of pads are then trimmed out.

Abstract: A method of manufacturing a bra pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each summit of a bra or bra-like garment for including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the summits of the breasts.

Abstract: A method of manufacturing a breast-covering garment pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each breast summit of the pad or a garment including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the nipples the breasts.

Abstract: A method of manufacturing a bra pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each summit of a bra or bra-like garment for including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the summits of the breasts.

Abstract: A method for making a pad includes pre-laminating a pair of foam sheets with fabric, shaving the foam from a first end of each foam sheet so that it gradually becomes thinner until only fabric is existent at an opposite second end, attaching the fabric and foam assemblies via the fabric at the second ends to form a pre-form assembly, molding the pre-form assembly to form a pair of cup-shaped members, and trimming off material around the cup-shaped members to form a pair of pads. The method further includes molding a second sheet of fabric, enclosing a formed pad in the second sheet of fabric, and trimming off the second fabric material around the edges of the formed pad. The formed pad is thickest at the bottom for support and becomes thinner until there is only fabric along the neckline to blend in with the skin of the wearer.

Abstract: A method of manufacturing a bra pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each summit of a bra or bra-like garment for including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the summits of the breasts.

Abstract: A method of manufacturing a bra pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each summit of a bra or bra-like garment for including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the summits of the breasts.